Bakster
I can imagine though that VF offers its own problems. If you don't mind me asking. What issues did you see with vacuum form?
I had three problems with the vacuum canopies Steve. The first was cutting them out. That was a real hairy experience since one mistake can destroy the canopy. I didn't do as good job of getting nice clean cuts as I would have liked. Most likely that is an experience issue. But as a result of the cuts I made, the canopies didn't give a really snug fit to the airframe.
The second issue arose when I was masking the canopy frame. I found some of the details for the frame a bit "soft" and so it made it a little more difficult to mask them off. When I first tried to use Tamiya tape I couldn't really decide where I should cut the tape to make the masks. Fortunately the bare metal foil I switched to was so thin I could easily see where to scribe the masks (the BMF had another set of issues with the adhesive... sigh). The soft details could be a specific issue with this particular canopy, or it may be a general problem with vac formed canopies. I don't have enough experience with them to know.
Issue number three is that the plastic used in not as rigid as styrene, and this led to some "fit" issues when I was trying to attach the canopies. After separating the three sections for the rear of the canopy the different pieces did not retain their proper widths. The main canopy section pulled in too narrow and the last section of canopy splayed a bit too much out. Because of this, and the slow curing time of the clear parts cement it was very difficult to get the parts to conform to the width of the airframe while the glue was setting. In the end I switched to CA and tacked down the main canopy section with the two smaller pieces simply tucked inside. Again, it could just be a specific problem with this particular canopy since I had to section the single piece molded part into five separate pieces to create an open canopy.
One final comment on the vac formed canopy that I didn't really think about until the end was that I had to drill holes in the windshield to fit the torpedo sight on. That was another really hairy moment as I had visions of a slip of the drill or files scratching the canopy just at the end of the project!
By the way, if anyone has gotten to the end of this diatribe and has any solutions to my issues, I'd be happy to hear them.